Structural connector and related assembly method using same

ABSTRACT

A structural connector for a manufacturing assembly includes a body portion sized to be substantially fitted into an open end of a first hollow structural component of a manufacturing assembly. The structural connector includes at least one flexible cantilevered ear portion which is sized to engage with a corresponding lateral opening provided in the first hollow structural component. Once seated, the connector accepts at least one fastener extending laterally through a second structural component which is fitted orthogonally, relative to the open end of the first structural component, permitting interconnection between the second structural component and the first structural component.

FIELD OF THE INVENTION

This invention relates to the field of manufacturing assemblies and in particular to a structural connector used in manufacturing assemblies defined by at least two or more structural hollow structural members, such as box beams, and a preferred method of assembly using at least one said structural connector.

BACKGROUND OF THE INVENTION

There are a variety of known manufacturing assemblies, such as those for free standing displays, scheduling boards, easels, and the like, that comprise a frame that requires the interconnection of at least two box beams in which some of the beams form joints with one another. Quite often, these beam members are made from an extruded aluminum or other lightweight material in order to provide sufficient strength and rigidity to the overall structure. The beams are essentially hollow and require the use of fasteners when mating the beams together, particularly those beams that interconnect with one another in the formation of orthogonal connections.

In a prior known assembly method design, depicted in FIG. 1, each of a pair of box beams 20 include a pair or more of interior grooves or bosses 22 that extend along the entire length of the interior of the hollow member to permit at least one fastener to be engaged therewith within a defined opening 24. The addition of these interior bosses, however, provide additional weight to the beams as well as increased material costs to the overall manufacturing assembly. Removal of the bosses in the center of the beam; that is, the axial portion of the box beam that does not require the use of fasteners would obviously ease some of the above concerns, but performing such removal would be extremely difficult, costly and time consuming.

SUMMARY OF THE INVENTION

Therefore, there is a general need in the field of manufacturing assemblies to minimize the weight of assembled structures such as those described above which include the interconnection of at least one pair of box beams, but without sacrificing structural integrity.

There is another compelling need to improve or reduce costs in the manufacture of structures, such as those that are described above.

Therefore and according to a preferred aspect of the present invention, there is described a connector for mating at least two structural components, said connector being matingly fitted into a tubular end of a first structural component wherein said connector includes at least one flexible cantilevered ear portions, said at least one cantilevered ear portion having a protrusion for engaging a lateral opening of the tubular end of the first structural component when said connector is attached thereto, thereby securing said connector.

Once seated, the connector permits the engagement of at least one fastener, thereby permitting the attachment of a second structural component to the first structural component. The connector is seated within the open end of the tubular structural component wherein the second component can be assembled to the end containing the connector. Additionally, securing the at least one fastener to the connector also prevents the connector from being removed from the at least one structural component in that the fastener is mounted into the open region or gap that permits flexion of the cantilevered ear portions.

According to another preferred aspect of the present invention, there is disclosed an assembly method for interconnecting at least two structural components, said method comprising the steps of:

-   -   inserting a structural connector into one open end of a first         hollow structural member, said structural connector comprising a         body portion which is sized to substantially engage the open end         of said member end and including at least one flexible         cantilevered ear portion;     -   pushing said structural connector until protrusions of said at         least one flexible cantilevered ear portion is caused to extend         into a corresponding lateral opening provided in said structural         member, thereby fixing said connector;     -   aligning a second hollow structural member onto said tubular end         of said first structural member such that fastener holes of said         second structural member are axially aligned with corresponding         fastener holes of said structural connector; and     -   mounting said fasteners through the aligned fastener holes so as         to fix said structural components together.

According to another preferred aspect of the present invention, there is disclosed an assembly comprising at least two hollow structural components, wherein a first of said structural components includes an open tubular end, said structure further including at least one structural connector for interconnecting said at least two hollow structural components, said at least one structural connector including a body portion sized to be substantially fitted into the open end of a structural component and having at least one flexible cantilevered ear portion, said at least one flexible cantilevered ear portion including a protrusion sized to engage a corresponding lateral opening in said structural component when seated therein.

Preferably, the structural connector includes a pair of flexible cantilevered ear portions on opposing lateral sides thereof wherein the structural connector and/or the at least one flexible cantilevered ear portion is made from a molded lightweight durable plastic, though it will be readily apparent that other suitable materials could be contemplated.

An advantage realigned by the present invention is that an effective manufacturing method is realized that does not impact the structural design of an assembly, but which can influence the overall weight and cost thereof.

These and other objects, features and advantages will become readily apparent from the following Detailed Description which should be read in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial perspective view of a box beam used in a manufacturing assembly that is made in accordance with the prior art;

FIG. 2 is a partial perspective view of a manufacturing assembly in accordance with a first embodiment of the present invention;

FIG. 3 is an exploded view of a portion of the manufacturing assembly of FIG. 2 illustrating the interconnection of a pair of intersecting structural components using a structural connector made in accordance with a first embodiment of the present invention;

FIG. 4 is a side view of the manufacturing assembly of FIG. 3, shown partially in section, showing the structural connector prior to insertion into the tubular end of a first structural component;

FIG. 5 is the side view of FIG. 4, showing the insertion of the connector into the end of the first structural component;

FIG. 6 is a side view, also partly in section, illustrating the attachment of a second interconnecting structural component following the assembly of the structural connector with the first structural component of FIGS. 4 and 5;

FIG. 7 is a perspective view of a structural connector made in accordance with a second embodiment of the present invention; and

FIG. 8 is an end view of the structural connector of FIG. 7.

DETAILED DESCRIPTION

The following description relates to a pair of embodiments of a structural connector as described for use with a specific manufacturing assembly. It will be readily apparent, however, from the discussion that follows that other suitable connector designs can be imagined using the inventive concepts described herein and that a number of suitable uses other than the specific manufacturing assembly depicted will be available by those of ordinary skill in the field. In addition, certain terms are used throughout the present discussion in order to provide a suitable frame of reference with regard to the accompanying drawings, such as “top”, “bottom”, “lateral”, “square”, “longitudinal”, “end” and the like. It is not intended, however, except where specifically indicated otherwise, that these terms are intended to be restrictive of the scope of the present invention.

Referring to FIG. 2, there is shown a portion of a manufacturing assembly 40 that includes a number of intersecting tubular structural components 44, 48 and 49 that are fitted into a T-like configuration. Each of the tubular structural components 44, 48, 49 shown is hollow and include opposing open ends 50, 52 wherein and in this instance, component 49 forms a portion of a base of the assembly with component 48 forming a vertically disposed leg and component 44 forming a horizontal cross member, for example, for an easel or similar assembly. For purposes of the discussion that follows, a single connection between intersecting structural components is described, and more particularly the interconnection between the components 44 and 48, though it will be readily apparent the following discussion applies as well, for example, to the interconnection between the components 48 and 49, shown as 51.

As shown in FIG. 3, a structural connector 56 is fitted into one open end 50 of a first tubular structural component 44, the connector preferably being made from a lightweight plastic material that can be molded or casted, such as acrylonitrile butadiene styrene (ABS) or a polyamide or polyethylene, though it will be readily apparent that other suitable materials, including stainless steel can alternatively be used.

Referring to FIGS. 3-6 the structural connector 56, according to this embodiment, includes a body portion 60. The body portion 60 is defined by a facing surface 67 at one end as well as a pair of exterior walls 61 disposed on opposing lateral sides thereof. The structural connector 56 further includes a pair of parallel interior walls 62, each of which extend between each of the exterior walls 61 and extend over the entire length of the connector, wherein the interior walls and the interior of the facing surface 67 combine to form an open-ended inner cavity 68. Each of the interior walls 62 and the exterior walls 61 of the herein described connector 56 terminate at the end opposite the facing surface 67 at a base portion 74. Extending from the base portion 74 in a direction parallel to the interior walls 62 and disposed outwardly spaced from each of the interior walls are corresponding flexible cantilevered ear portions 72 which span an intermediate length of the structural connector 56. The herein described ear portions 72 are spring-like in that they are sufficiently flexible and biased to spring outwardly either toward or away from the envelope of the body portion 60. Each of the flexible cantilevered ear portions 72 includes a circular protrusion or plug 76 at the cantilevered end thereof that extends outwardly from the envelope of the body portion and is sized to engage a corresponding lateral opening 80 of a tubular structural component 44 into which the structural connector 56 is seated, as is described in greater detail below. A pair of fastener holes 91 is provided in the facing surface 67 that is aligned with a corresponding pair of fastener holes 93 extending through the base portion 74. Each pair of fastener holes 91, 93 is aligned outboard of the interior walls 62 and inboard of the flexible cantilevered ear portions 72, wherein recesses 78 are provided between each of the interior walls and flexible cantilevered ear portions 72 sized for receiving a fastener and for permitting inward flexion of the ear portions 72, as described below. It should be pointed out that though two ear portions are shown, that the connector could be alternately made, for example, with a single ear portion. It should be further pointed out that the shape of the protrusion 76, though circular according to the present embodiment, can be varied depending on the shape of the lateral opening provided that the protrusion provide some form of extension beyond the envelope of the body portion when the ear portion is in a nominal unbiased position in order to provide engagement with the opening.

It should be further pointed out that varying configurations of the herein structural connector body design are possible, depending on the shape of the tubular structural component into which the structural connector 40 is fitted as well as other considerations, such as the type of assembly that the connector(s) is being used. In the embodiment described herein, a substantially rectangular cross section for a box beam is described, however, it will be readily apparent that similar connector configurations can be made to conform to other shapes, such as circles, ovals, triangles, and polyhedral configurations. In addition, and though only two flexible cantilevered ear portions 72 are detailed herein, it should also be readily apparent that any number of such features could be used to effect attachment, as described in greater detail below.

In terms of assembly and referring to FIGS. 4-6, the structural connector 56 is initially engaged into the open tubular end 50 of the first structural component 44 and inserted with the facing surface 67 of the connector body portion 60 facing outwardly; that is, the end of the connector having the base portion 74 is inserted first into the tubular end. As the structural connector 56 is inserted within the open tubular end 50 of the first structural component 44, each of the flexible cantilevered ear portions 72 are caused to deflect inwardly toward the interior walls 62 of the connector due to the size mismatch between the protrusions 76 of the ear portions and the interior surface of the structural component, as shown more clearly in FIG. 5. As a result of this mismatch, the cantilevered end of each of the ear portions 72 are caused to bow inwardly into the recess 78 provided between each ear portion and the interior wall 62. Referring to FIG. 6 and as the structural connector 56 is further pushed into the open tubular end 50 of the tubular component 44, the protrusions 76 are aligned with the lateral openings 80 of the structural component 44 and the initial biasing force of the flexible cantilevered ear portions 72 causes the ear portions to spring outwardly and the protrusions 76 to extend through the openings, effectively seating the structural connector 56 in place.

Still referring to FIG. 6, the second structural component 48 can then be attached to the above created subassembly. According to this embodiment, the second structural component 48 is also a box beam having a nearly identical construction to that of the first structural component 44. The second structural component 48 further includes two pairs of aligned fastener holes 88, 89. Each of the fastener holes 88, 89 are axially aligned with the fastener holes 91, 93 that are provided in the structural connector 56. Corresponding threaded fasteners 90 are then added for mounting to provide an effective joint connection between the first and second structural components 44, 48 with the fasteners being seated within the base portion 74 and the structural connector 56 firmly engaged with the first structural component 44. According to the present embodiment, the fasteners are sized such that the heads of the fasteners 90 engage with the interior surface of the second structural component 48 and caps 98 are preferably added to cover the openings 88 following assembly of the components. Alternatively, the fasteners can be made longer with the head of the fasteners engaging the exterior surface of the second structural component. As previously noted, all similar remaining connections between structural components of the herein described manufacturing assembly 40 (e.g., components 48, 49) are performed in a like manner using another structural connector 56 (not shown).

It should be readily apparent that the number of fasteners can be varied for use with the structural connector 56 and that the pair shown is intended to be merely exemplary.

Once the fasteners 90 are attached, the structural connector 56 cannot be removed from the first structural component 44 in that the shank of the fasteners now occupy the recesses 78 that permits flexion of each of the cantilevered ear portions 72. As a result, the presence of the fasteners 90 restricts the ability of the user to inwardly press the protrusions 76 in an effort to release the structural connector 56.

Variations to the design of the structural connector are possible. For example, a second version of a structural connector 110 is shown in FIGS. 7 and 8. This structural connector 110 includes a body portion 114 that is defined by a lower base portion 115 and a coextensive upper portion 117. The lower base portion 115 is sized and shaped to fit within the open end of a first structural component. The upper portion 117 is also rectangular in configuration and is defined by four lateral side walls and a facing side, the upper portion being smaller in width than that of the lower base portion 115 which is also rectangular in configuration according to this embodiment. A pair of flexible cantilevered ear portions 118 extends from opposite lateral sides of the lower base portion 115, each of the ear portions extending a portion of the overall length of the structural connector 110 and including a protrusion or plug 122 at a cantilevered end thereof. A pair of fastener holes 130 is provided in the base portion 115, each of the holes being outboard of the upper portion 117 and inboard of the ear portions 118, wherein the holes extend through the entirety of the base portion. As such, a gap 134 is established between a pair of opposite lateral side walls 126 of the upper portion 117 and the flexible cantilevered ear portions 118.

In terms of assembly, the structural connector 110 is seated with the tubular open end of a first structural component such as that previously described (not shown) with the end having the base portion 115 being inserted first. The connector is sized such that the ear portions 118 are caused to inwardly flex toward the lateral side walls 126 of the upper portion 117 due to the size mismatch between the protrusions 122 and the interior wall of the first structural component. Further insertion of the structural connector 110 causes the protrusions 122 to pass lateral openings in the component and cause the ear portions 118 to be restored to their original position due to the biasing spring force caused by their flexion, fixing the structural connector in place. A second structural component can then be attached by passing fasteners (not shown) through respective holes aligned with the fastener holes 130 provided in the base portion 115 of the connector 1 10 wherein the heads of the fasteners will engage the interior wall of the second structural component. Caps (not shown) can then be added to cover the exposed openings of the second structural component.

Parts List for FIGS. 1-6

20 boxbeam

22 beam sections

24 bosses

26 fastener holes

40 manufacturing assembly

44 tubular (first) structural component

48 tubular (second) structural component

49 tubular structural component

50 open end

52 open end

56 structural connector

60 body portion

61 exterior walls

62 interior walls

67 facing surface

68 inner cavity

72 flexible cantilevered ear portions

76 protrusions

78 recesses

80 lateral openings

88 fastener holes

89 fastener holes

90 fasteners

91 opening

93 opening

98 caps

110 structural connector

114 body portion

115 lower base portion

117 upper portion

118 flexible cantilevered ear portions

122 protrusions

126 lateral side wall

130 fastener holes

134 gap

Though the present invention has been described in terms of certain preferred embodiments, it will be readily apparent that variations and modifications are possible to those of sufficient skill in the field in accordance with the claims as follows. 

1. A structural connector for a manufacturing assembly involving at least two hollow components, said structural connector comprising: a body portion adapted to be fitted substantially within an open end of a hollow first component; at least one flexible cantilevered ear portion extending from said body portion, said at least one ear portion including a protrusion sized to extend into a lateral opening in said first component for fixing said connector therewith; and means for receiving at least one fastener for permitting interconnection between said first component and a second hollow component that is disposed orthogonally relative to said open end of said first component.
 2. A structural connector as recited in claim 1, wherein said fastener receiving means includes at least one fastener hole disposed in a base portion of said connector.
 3. A structural connector as recited in claim 1, wherein at least a portion of said structural connector is made from a highly flexible material.
 4. A structural connector as recited in claim 1, wherein said connector is made from a molded plastic.
 5. A structural connector as recited in claim 1, wherein said connector body portion is sized to seat substantially entirely within the open end of said first structural component.
 6. A structural connector as recited in claim 1, including a pair of flexible cantilevered ear portions disposed on opposing lateral sides of said body portion.
 7. A structural connector as recited in claim 6, including a pair of internal walls defining an inner cavity, said flexible cantilevered ear portions being disposed parallel to said internal walls and outboard therefrom.
 8. A structural connector as recited in claim 7, including a recess between said internal walls and said ear portions into which said ear portions can inwardly flex.
 9. A method for interconnecting at least two components of a manufacturing assembly, said method comprising the steps of: inserting a connector into one open end of a first hollow structural component, said connector comprising a body portion sized to substantially engage the open end of said first structural component and including at least one flexible cantilevered ear portions; inserting said connector into said open end until a protrusion formed at the end of said at least one flexible cantilevered ear portion is caused to extend into lateral openings formed in said first structural component, thereby fixing said connector; aligning a second hollow structural component relative to the open end of said first structural member such that fastener holes of said connector are axially aligned with corresponding fastener holes of said second structural component; and mounting fasteners through the aligned fastener holes to fix the first and second structural components together.
 10. A method as recited in claim 9, wherein said second hollow structural component is disposed orthogonally relative to the open end of said first structural component.
 11. A method as recited in claim 10, including the step of additional steps of mounting at least a third structural component to said assembly using a said connector.
 12. A manufacturing assembly comprising: at least two structural components, each of said components being hollow and including at least one open end; and at least one connector for interconnecting at least two of said components, said connector including a body portion sized to be substantially fitted into the open end of a first structural component and further including at least one flexible cantilevered ear portion, said at least one ear portion including a protrusion sized for engaging a lateral opening formed in the open end of said first structural component when said connector is seated therein.
 13. An assembly as recited in claim 12, wherein said at least one flexible cantilevered ear portion is made from a molded plastic material.
 14. An assembly as recited in claim 12, wherein said connector is entirely made from a molded plastic.
 15. An assembly as recited in claim 12, wherein each of said structural components are made of metal.
 16. An assembly as recited in claim 12, wherein each of said structural components is made from extruded aluminum.
 17. An assembly as recited in claim 12, wherein the body portion of said connector includes means for retaining at least one fastener, said second structural component being arranged orthogonally relative to the open end of said first structural component and having aligned openings permitting the passage of said at least one fastener through said openings of said second component, thereby permitting said first and second structural components to be attached to one another.
 18. An assembly as recited in claim 17, wherein said connector includes a pair of interior walls defining an inner cavity and said ear portions are provided parallel to said interior walls and outboard relative thereto.
 19. An assembly as recited in claim 18, including a gap between at least one interior wall and said at least one ear portion, providing spacing to permit said ear portion to be flexed inwardly when said connector is initially inserted into the open end of said first structural component.
 20. An assembly as recited in claim 19, wherein said gap is sized to permit the passage of said at least one fastener when said second structural component is attached thereto.
 21. An assembly as recited in claim 20, wherein the passage of a said fastener into said gap prevents flexion of said at least one cantilevered ear portion.
 22. An assembly as recited in claim 12, wherein said connector includes at least one pair of flexible cantilevered ear portions, each of said pair of ear portions being disposed on opposing lateral sides of said body portion. 